The 3 rd Edition of the conference on Automotive R & D trends 2015 "Sustainable Mobility: Technologies, Systems, Best Practices Presentation Topic Collaborative Innovation in Product Development by Dr V BALASUBRAMANIAN Dr. V.BALASUBRAMANIAN EXECUTIVE DIRECTOR (ENGINEERING & DEVELOPMENT) M/S SIMPSON & CO CHENNAI 15 th Oct 2010
Welcome To Amalgamations Group The Amalgamations Group, like the banyan tree, has spread its beneficent shade way beyond its origins. And like a banyan tree, it has provided shelter to thousands, and has stayed deeply rooted to its values while reaching for the sky. The Group is unique not only for its diversity, but for its deep-rooted values such as product quality and customer satisfaction, a spirit of innovation, ethical practices, respect for the individual and a concern for society. The Group has the talents and tools, the vision and resilience, plus the wisdom and insights to keep the flag of Excellence flying high in any sphere of activity. The Amalgamations Group s activities fall under four broad categories: i) Engineering, including auto-related manufacturing activities ii) Trading & Distribution iii) Plantations iv) Services
AMALGAMATION GROUP Founder : Mr. S. Anantharamakrishnan Founded in : 1938 Members consisting of : 17 in Manufacturing : 10 in Trading & Distribution : 06 in Service Sectors : 03 in Plantations The Group Turnover : Over US $ 1.2 Billion (INR 5000 Cr.) SIMPSON & CO is a Member of the Amalgamations Group
MANUFACTURING COMPANIES Simpsons & Co Ltd (Diesel Engines) India Pistons Ltd (Piston, Pin, Rings & Liners) Addison Paints & Chemicals Ltd (Paints, Lacquers & Enamels) Tractor and Farm Equipment Ltd (Tractors) TAEF ACCESS Ltd (Farm Equip & Accessories) AMCO Batteries Ltd (Lead-Acid Batteries) Shardlow India Ltd (Crankshafts & Forgings) Bimetal Bearings Ltd. (Thin wall Bearings) IP Pins & Liners Ltd (Piston Pin & Liners) IP Rings Ltd (Steel Piston Rings) India Pistons-Repco Ltd (Flywheel ring Gear) MAHLE IP Ltd (Piston) Addison & Co Ltd (Cutting Tools & M/c tool Accessories) Amalgamations Repco Ltd. (Clutch Assemblies & Driven Plates) Amalgamations Valeo Clutch Ltd. (Clutch Assemblies) Stanadyne Amalgamations Ltd. (Fuel Injection Equipments) L.M. Van Moppes Diamond Tools India Ltd. (Diamond Tools)
MAJOR PRODUCTS MANUFACTURED
SIMPSON & CO Simpsons is perhaps one of the oldest business establishments in the country, with origins dating back to 1840. From 1840 to 1950 it pioneered the building of coaches and carriages, ornate railway coaches, motorcars, steam passenger buses and public service vehicles in India. Simpsons became synonymous with diesel power when it ushered in engine technology into India in 1955 through a Sales & Distribution Agreement with Perkins of U.K. Simpsons was the first Indian company to indigenously manufacture diesel engines for surface transport vehicles. Today it is India's leading manufacturer of high h performance diesel engines catering to a wide variety of applications ranging from 20 to 100 HP covering agriculture, industrial, vehicular, power generation and marine applications.
INDIA PISTONS Ltd India Pistons (IPL) was born in 1949 as the Group's first auto- ancillary manufacturing unit. Today it has a world-class facility with most advanced equipment to manufacture Pistons, Rings, Gudgeon Pins, Circlips and Cylinder Liners for IC engines that meet global standards of performance.
EXPECTATIONS of STAKE HOLDERS CUSTOMER FUEL & OIL CONSUMPTION MAINTENANCE COST RELIABILITY & LIFE MANUFACTURER DEVELOPMENT TIME & COST EMISSIONS NOISE VIBRATION & HARSHNESS The above are the KEY factors driving any New Product Development
CURRENT ( PROBLEM) OPPORTUNITY ISSUE: To reduce the Lube oil consumption and Blow By in a 4 Cylinder Naturally Aspirated Direct Injection Diesel Engine. Customer requirement for improvement in Oil consumption were reviewed. In this case specific requirement of reduction in oil consumption at operating condition was given special focus
CURRENT ( PROBLEM) OPPORTUNITY DESIGN CONCEPT: The piston is a conventional one with steel strut controlled expansion type. Problem of higher part load condition oil consumption can be attributable to strut type piston where the expansion is controlled, which creates more clearance passage for oil transport along Pin axis. The solution identified is the eliminating strut design. Based on the above collaborative innovation a comprehensive proposal was evolved with help of the vendor IPL. During this process, scope for improving the existing design by way of reduction of inertial masses (piston weight reduction), improvement in ring pack features to match recent trends were also taken up. Internally, Simpson modified & improved the method of bore honing. All the improvements were firmed up concurrently.
ENGINE SPECIFICATION S Series
INNOVATIVE UP GRADATION The focus parameters for improvement were short listed as: Non strutted ALFIN piston against steel strut piston currently used Piston inertial mass reduction of approx 10% Modified Piston ring pack with features inline with modern trend Enhancement of Piston design features for good Oil control & improved drainage. Cylinder liner bore finish with Plateau honing feature. Reduced distortion of cylinder bore achieved through torque plate honing
INNOVATIVE UP GRADATION PISTON DESIGN MODIFICATION CURRENT MODIFIED Steel strut
INNOVATIVE UP GRADATION The prime requirements are reduction of Engine Oil consumption & Blow by gases with optimized Piston assembly and improved cylinder bore finish i. A concept design proposal is evolved out of basic design guideline established with due consideration covering benchmark database trend of similar engine application. To satisfy the requirement for a Design review, analytical techniques y q g, y q are necessary in the competitive environment, which leads us to take up Simulation & FEA analysis prior to validation.
Oil Consumption Mechanisms
Oil Consumption Mechanisms Simulation consists of Seven proprietary modules, calculation of these complex modules predicts Oil Consumption, Blow-by. Three main mechanisms considered for Oil consumption. a) Evaporation at o : Oil film present on the top portion o of the liner gets exposed to high temperature as the piston moves down. b) Throw-off off : Oil carried by top ring leading edge will be thrown into combustion chamber /exhaust during TDC reversal. c) Entrainment : Oil carried by the blow back gases into the combustion chamber from the clearance spaces between piston-bore and ring-grooves.
Design inputs considered Piston, ring pack and liner configuration and geometry. Material properties (Hardness & En) of rings, piston and liner. Surface finish parameters of the components. Lubrication oil properties. p Engine operating conditions. a. Engine speed. b. Cylinder gas temperature over a cycle. c. Cylinder gas pressure over a cycle (P-Theta). d. Crankcase gas temperature & pressure over a cycle. Temperature distribution of the piston and liner by software simulation.
ANALYTICAL APPROACH PISTON ANALYSIS Three-dimensional geometrical models of the piston assembly is designed based on the Inertial and friction factors, the design parameters of piston are reviewed to improve the functional requirement by converting Steel Strut piston to Non-strut, Internal Core shape was optimized based on design guideline to match the current piston trend. Piston ring pack was selected for the designed d piston. The Design has been fully analyzed by 3D finite element analysis and meets all the strength and temperature criteria. The focus is been directed toward the Performance Implication before proceeding into the Engine.
ANALYTICAL APPROACH RINGPAK ANALYSIS A professional software was used as a simulation tool for investigating the lube oil consumption and Blow by generating ring dynamics in the existing engine & modified ring pack configuration
SIMULATION RESULTS Comparison of Oil Consumption and Blow by for Base and Proposed Configurations through Simulation
EXPERIMENTAL TEST MATRIX ENGINE BORE PISTON RINGS TEST NO: Spec. Spec. Spec. CYCLE 04303 Current Current Current FLRS 04303 Current Current Current PL 04303 Current Current Current DC 04576 Modified Modified Modified FLRS 04576 Modified Modified Modified PL 04576 Modified Modified Modified DC 04686 Modified Modified Modified FLRS 04686 Modified Modified Modified PL 04686 Modified Modified Modified DC FLRS : Full Load Rated Speed PL: Part Loads DC: Duty Cycle ( field Data)
ENGINE UP GRADATION RESULTS OF THE EXPERIMENT : (*) This data will be changed in presentation The chart shows the comparative results from two engines with modification as compared to the current engine. ENGINE NO ENGINE STATUS TEST CYCLE LOC (gms/hr) BLOW BY (lpm) 04303 Std ( Before) FLRS 15.8 35 04303 Std ( Before) PT 11.2 30 04303 Std ( Before) LOC 11.6 30 04576 Modified (After) FLRS 14.6 25 04576 Modified (After) PT 9.4 23 04576 Modified (After) LOC 9.8 21 04686 Modified (After) FLRS 11.2 24 04686 Modified (After) PT 7.9 22 04686 Modified (After) LOC 7.8 20
ENGINE ENDURANCE ENDURANCE TEST 500 Hrs: In order to validate the improvement obtained on the engine with the In order to validate the improvement obtained on the engine with the modification, it was decided to carry out a 500 hrs Full Load rated speed endurance on the engine dynamometer in our R&D.
RESULTS- ENGINE ENDURANCE (500 Hrs) ENDURANCE TEST BLOW BY (lpm m) 45 40 35 30 25 20 15 10 5 0 0 100 200 300 400 500 ENDURANCE HOURS (hrs) BEFORE AFTER ENDURANCE TEST ) LOC (kg/hr) 20 18 16 14 12 10 8 6 4 2 0 0 100 200 300 400 500 ENDURANCE HOURS (hrs) FLRS BEFORE FLRS AFTER
CONCLUSIONS Engine with the modified piston, ring pack & improved bore condition resulted in ; Reduction in oil Lube oil consumption by ~10% in FLRS & by~15% in PL/DC Overall reduction in engine blow by~ 25% Performance was satisfactory after 500 Hrs Engine Endurance test.
Innovative improvements in a product with a collaborative approach has resulted in benefit to all the stake holders.
Thank you ALL